Académique Documents
Professionnel Documents
Culture Documents
Table Of Contents
Description
Page
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Receiving, Handling and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Standard Production Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Operational Check Prior to Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Inspection, Maintenance and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
R-MAG 15.5 kV Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
R-MAG 27 kV Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Appendix A: Installation/Maintenance Instructions ED2.0 Magnetic Actuator Control Board . .28
List Of Illustrations
Description
Page
2.0 INTRODUCTION
These instructions do not attempt to provide the user of this equipment with every possible difficulty that may occur in the application, operation and maintenance of the product. Also, as
improvement in parts and assemblies are made, some parts may differ in appearance as depicted in the illustrations; however, functionality will be equivalent.
The Type R-MAG vacuum breaker is a high-voltage, three-phase device incorporating three vacuum interrupters, gang operated by a magnetic actuator. Together with the optional relaying and
current transformers, the breaker will sense an overload and automatically open.
Satisfactory performance of the breaker is contingent upon the correct installation, and adequate
maintenance and service of the product. Careful study of these instructions will permit the user to
obtain maximum benefit from this device.
3.3 Storage
For prolonged storage, indoor storage is recommended. If stored outdoors, the cabinet heaters
must be energized to maintain the warranty. The mechanism and control compartment is
equipped with heaters to reduce condensation.
6.0 OPERATION
6.1 Closing
In the open position, the magnetic actuators armature rests against the bottom plate in the actuator assembly. The armature is held there by the force developed by the magnet. When the top coil
is energized, the magnetic flux generated is in the same direction as the magnet assembly. The
armature is drawn into the coil and brought into contact with the upper plate. In this position, the
coil is de-energized and the armature is held in position by the magnet alone. As the armature is
drawn into the coil, the operating rod, which is attached to the top guide rod, moves the moving
contact of the vacuum interrupter towards the closed position. The actuator has more stroke than
the vacuum interrupter and the interrupter contacts make contact before the actuator has completed the stroke. The additional movement of the operating rod after the contact closing causes the
contact pressure spring to compress at the top of the operating rod. This over-travel allows for
contact wear in service.
6
6.2 Opening
When the bottom coil is energized, the magnetic flux opposes the force generated by the magnet
assembly. This reduces the holding force, the armature is released and the coil attracts the armature to the bottom plate. Once there, it is held open by the magnet.
RADIATION WARNING: High voltage applied across an open gap in a vacuum can produce Xradiation. No radiation is emitted when the interrupter is closed, since no gap exists. Also, when the
breaker is open to the specified contact spacing in service or tested within the voltages specified,
X-radiation at one meter is below the level of concern. A danger could exist at voltages above or
contact spacing below that specified on the nameplate.
1. With the breaker in the open position, jumper both sets of three top terminals together. Ground
one set of terminals and the housing. Connect the high voltage to the other set of terminals.
2. Stand clear more than one meter before energizing the high voltage source.
3. Apply a test voltage of 37.5 kVAC for one minute. Do not exceed 37.5 kVAC.
4. If internal flashover occurs, isolate the phases and test each one independently to identify the
defective interrupter. Any defective interrupter must be replaced prior to the breaker being
placed in service.
7
8.0 INSTALLATION
The breaker must be be vertical, level and securely fastened. Follow your company guidelines
and codes for setting the height of the breaker, securing the frame to the pole or foundation, and
making connections.
8.1 Mounting
The breaker is normally shipped suitable for substation mounting. The following is the recommended installation procedure:
Substation Mounting:
1. With the lifting brackets mounted to the breaker roof, lift the breaker off the pallet and move
into position.
2. Bolt the legs to the pad and raise the upper portion to the desired height.
3. Bolt the legs to the sides of the breaker.
4. Make sure all hardware is tight.
8.2 Grounding
The breaker cabinet has two ground parts, one on each side sheet. It is important that both of
these be connected to the ground grid with #6 or larger wire. If the ground pad is provided on the
roof, it should be connected to the ground pad on the side sheet.
8.3 Arrester Protection
ABB recommends that surge arresters be properly applied in the substation.
8.4 Control Power
Supply the control power as indicated on the wiring diagram. If 240 VAC is used, verify the connections for the heaters before applying power. Check all terminal block connections for proper
tightness. For details of the overall control circuit, refer to the specific wiring diagrams supplied
with the breaker.
8.5 Final Inspection
When the breaker has been installed and all mechanical and electrical connections completed,
EXCEPT ENERGIZING THE POWER LINE, the following points of inspection are recommended:
1. Ensure the breaker is properly leveled and securely anchored.
2. Make a final check of tightness of all hardware.
3. Check that the heaters work.
4. Securely tighten terminal and ground connections.
5. Check control cable entrance fittings for tightness.
6. Operate the breaker from the control box to verify normal operation.
7. Secure all doors and ensure proper gasketing for weather.
8. Ensure that all tools are removed.
8
RADIATION WARNING: High voltage applied across an open gap in a vacuum can produce Xradiation. No radiation is emitted when the breaker is closed, since no gap exists. Also, when the
breaker is open to the specified contact spacing in service or tested within the voltages specified,
X-radiation at one meter is below the level of concern. A danger could exist at voltages above or
contact spacing below that specified on the nameplate.
1. With the breaker in the open position, jumper both sets of three top terminals. Ground one
set of terminals and the housing. Connect the high voltage to the other set of terminals.
2. Stand clear more than one meter before energizing the high voltage source.
3. Do not exceed 37.5 kV.
4. If internal flashover occurs, isolate the phases and test each one independently to identify
the defective interrupter. Any defective pole assembly must be replaced prior to the breaker
being in service.
9.2 Replacement of Vacuum Interrupter Assemblies (See Figures 3-8)
The following procedure is made with the R-MAG breaker in the open position, control power off
and locked out, and stored energy capacitors discharged.
CAUTION
If power is removed from unit, and the Dip Switch I1004-1 is placed in the on
position, the breaker will automatically trip in approximately 3 minutes. Make
sure personnel and tools are clear from breaker.
Removing the existing interrupter assemblies:
1. Using pliers, expand the "X" type retaining rings (G) at the top of the pullrod (A) and disconnect the pullrod from the triangle bellcranks. (Figure 8)
2. Loosen hardware at the point where the bottom of the bushing studs attach to each end of
the top of the interrupter bus assemblies (M) and remove hardware. (Figures 3-7)
3. Loosen the mounting hardware that fastens the interrupter assembly to the top of the
insulators (N). (Figures 3-7)
4. With the loosened hardware removed, lift the interrupter assembly from the breaker. Repeat
for all three phases.
Installing the new interrupter assemblies:
5. Replace with new interrupter assemblies (contact ABB for instructions on installation) on all
three phases using the new hardware provided. (Figures 3-7)
6. After all interrupter assemblies are in place, reinstall the triangle bellcranks to the top of the
pullrod (G) using the new "X" type retaining washers provided and compress the "X" rings
with pliers. (Figures 3-7)
10
7. Support the moving contact of the vacuum interrupter at the contact block (C) and loosen the
nut (F) taking care not to apply any torque to the end of the vacuum interrupter as damage
may result. (Figures 8).
8. With the stem nut loose (F), install the shoulder pin and washers through the triangular bellcranks) to the bolt stem (B) (E) and fasten with the new locknut provided.
9. Install the opposite end of the new bellcranks to the top of the pullrod (G) using the new "X"
type retaining washers provided and compress with pliers.
10. Torque the bolts and connections at (M) (N) per the torque specifications in section 9.0.8.
DO NOT TIGHTEN THE BOTTLE STEM NUT (F) ON THE VACUUM INTERRUPTER UNTIL
INSTRUCTED TO DO SO.
11. Ensure that the locknut (F) on the bolt stem (E) is loose while supporting the moving contact
to prevent any torque from being exerted on the internal bellows of the vacuum interrupter.
12. Remove the shoulder bolt (B) while applying pressure from the back of the contact block.
Allow the contact block to move slowly to the closed position. Caution: Finger pinch point.
13. Loosen the pullrod locknut (D).
14. Turn the pullrod until the center of the hole for the shoulder bolt (B) is 1.687" from the contact block (C). (This step sets a reference point for the bell cranks.)
15. Spin the bolt stem (E) until the shoulder bolt (B) can be inserted, then remove the shoulder
bolt (B). (This step establishes a reference from VI contact to the bell cranks.)
16. Spin the bolt stem (E) 6 to 6.5 full turns (6.5 turns is preferred final travel, but 6 is acceptable
prior to contact conditioning) clockwise. (This step sets the contact travel.)
17. Pull from back of contact block (C) until shoulder bolt (B) can be inserted.
18. Install a new locknut and tighten all hardware. Note: When tightening the nut (F) on the stem
bolt (E), support the moving contact at the contact block (C) to prevent any torque from
being exerted on the internal bellows of the vacuum interrupter as damage may result.
19. Do not reuse washers.
20. Operate the breaker a minimum of 200 times to season the new contacts, and then readjust
the breaker (Step 9-19). Proceed to section 9.3 for final adjustment.
9.3 Contact Travel and Over-Travel Adjustment (See Figure 8) (Control power required)
1. Measure travel and over-travel by opening and closing the breaker. Confirm the breaker is
within the limits below (by voltage rating). While the breaker is in the closed position, minor
adjustments can be made by loosening the nut (D) and rotating the pullrod (A). Make sure all
hardware is tightened before operating the breaker and proceed to step 2 below by your
breaker voltage rating.
2. Over-travel gaps (L) (produced at top of each pullrod while the breaker is in the closed position) are recommended to be set from 0.170 to 0.260" (when measuring breakers in operation, it is acceptable to be 0.125).
3. Travel limits (K) (difference in measurements between contact block in open and closed position) are:
For 15.5 kV breakers = 0.413" to 0.492" (10.5 mm - 12.5 mm).
For 27 kV breakers = 0.591" to 0.630" (15.0 mm - 16.0 mm).
11
12.5 kA Interruption
16 kA Interruption
20 kA Interruption
25 kA Interruption
Figure 15. Typical Outline 15.5 kV, 2000/3000/3700 A and 27 kV, 1250/2000 A
23
Temperature Range
Dielectric Strength
Low Frequency Withstand
Dry 60 Hz 1 minute
Wet 60 Hz 10 seconds
Full Wave Withstand
Minimum Creep to Ground (External)
ANSI Standard Operating Duty
Interrupting Time
Permissible Tripping Delay (Y)
Reclosing Time
Interrupting Ratings
Short-Circuit (At Contact Part) RMS R1
Short-Circuit (At Contact Part) RMS R2
Short-Circuit (At Contact Part) RMS R3
Short-Circuit (At Contact Part) RMS R4
Close and Latch (Initial Current Loop) Peak
Transient Recovery Voltage (time to peak = 36 sec)
Load Current Switching Capability
Rated Line Charging Breaking Current
Rated Cable Charging Breaking Current
Rated Isolated Capacitor Bank Breaking
(Definite Purpose)
Rated Back-to-Back Capacitor Bank Breaking
(Definite Purpose)
Rated Capacitor Bank Inrush Making
Rated Capacitor Inrush Frequency
Mechanical Life
Between Servicing
No-Load Mechanical
Continuous Current Switching
15.5 kV
1.0
600 A
800 A
1250 A
2000 A
3000 A
3700 FA
-50C to +55 C
50 kV RMS
45 kV RMS
110 kV BIL
17.8 inches
O-0.3s-CO-3Min-CO*
3.0 cycles (seconds)
2 seconds
0.3 seconds
12.5 kA Sym / 14.5 kA Asym
16.0 kA Sym / 18.5 kA Asym
20.0 kA Sym / 23.2 kA Asym
25 kA Sym / 29 kA Asym
2.6 x Sym interrupting rating
29 kV peak
same as continuous current rating
100 A
600 A
600 A
600 A
20 kA
4240 Hz
2,000
10,000
10,000
*Operating duty conforms to old ANSI Standard (actual time can be CO-15 Sec-CO).
24
27 kV
1.0
1250 A
2000 A
-50C to +55 C
60 kV RMS
50 kV RMS
125/150 kV BIL
27.5 inches
O-0.3s-CO-3Min-CO*
3.0 cycles (seconds)
2 seconds
0.3 seconds
12.5 kA Sym / 14.5 kA Asym
16.0 kA Sym / 18.5 kA Asym
20.0 kA Sym / 23.2 kA Asym
25 kA Sym / 29 kA Asym
2.6 x Sym interrupting rating
51 kV peak
same as continuous current rating
100 A
400 A
400 A
400 A
20 kA
4240 Hz
2,000
10,000
10,000
*Operating duty conforms to old ANSI Standard (actual time can be CO-15 Sec-CO).
25
50-5
X2-X3
100-5
X1-X2
100-5
X1-X1
200-5
X1-X3
150-5
X1-X3
300-5
X4-X5
200-5
X4-X5
400-5
X3-X4
250-5
X3-X4
500-5
X2-X4
300-5
X2-X4
600-5
X1-X4
400-5
X1-X4
800-5
X3-X5
450-5
X3-X5
900-5
X2-X5
500-5
X2-X5
1000-5
X1-X5
600-5
X1-X5
1200-5
2000:5 MULTI-RATIO
3000:5 MULTI-RATIO
CURRENT TRANSFORMER CURRENT TRANSFORMER
TERMINAL
RATIO
TERMINAL
RATIO
X3-X4
300-5
X3-X4
300-5
X1-X2
400-5
X4-X5
500-5
X4-X5
500-5
X3-X5
800-5
X2-X3
800-5
X1-X2
1000-5
X2-X4
1100-5
X2-X3
1200-5
X1-X3
1200-5
X2-X4
1500-5
X1-X4
1500-5
X2-X5
2000-5
X2-X5
1600-5
X1-X3
2200-5
X1-X5
2000-5
X1-X4
2500-5
X1-X5
3000-5
26
INDUCTIVE CIRCUITS
MAKE AND BREAK (A)
CONTINUOUS
RATING (A)
24/48 VDC
16
16
20
125 VDC
10
10
20
250 VDC
20
115 VAC
15
15
20
230 VAC
10
10
20
BINARY INPUTS AC
- KM10051, 2
(INCLUDES TRIP
AND CLOSE)
BINARY INPUTS DC
KM10051
(INCLUDES TRIP
AND CLOSE)
AUXILIARY POWER
AC - KM10031
AUXILIARY POWER
DC - KM10031
The threshold for the binary inputs occurs at approximately 18 VDC or 19 VAC. The threshold for the protection relay input is approximately 7 VDC.
2
Binary input threshold depends on filter card jumpers. See section 3.0 of Appendix A.
27
APPENDIX A
28
Table Of Contents
Description
Page
1.0 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
2.0 ED2.0 BOARDS AVAILABLE/MAGNETIC COIL ENERGIZING CAPACITOR . . . . . . . . .31
3.0 BINARY INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.1 Remote Close (KM1005 Pins 1 & 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.2 Remote Open (KM1005 Pins 3 & 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.3 Auxiliary Open / Safe Open (KM1005 Pins 5 & 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
3.4 Protection Trip / Second Trip (KM1005 Pins 7 & 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.5 Circuit Breaker Locked Open (KM1005 Pins 11 & 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
3.6 Under Voltage Trip (KM1005 Pins 13 and 14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
29
1.0 OVERVIEW
The ED2.0 electronic control board is comprised of a Power Supply Recharge Unit, Control Unit,
and FET Switching circuit which connects the Storage Unit Capacitors to the Magnetic Actuator
coils.
The power supply recharge circuitry adapts whatever input voltage, within the specified range
(Section 2.0), is supplied to maintain an 80 V charge voltage across the capacitors. The Control
Unit monitors binary inputs and outputs, hardware and software configurations, position sensors,
capacitor charge, and switches the FET circuit to connect the capacitor voltage to the Magnetic
Actuator coils following an open or close command.
The Capacitor Storage Unit consists of two 0.1 farad Aluminum Electrolytic capacitors connected
in parallel to provide a total capacitance of 0.2 farad on the 15 kV rating. The Capacitor Storage
Unit consists of three 0.1 farad Aluminum Electrolytic capacitors connected in parallel to provide
a total capacitance of 0.3 farad on the 27 kV rating. The energy stored is approximately 640
Joules on 15 kV and 960 Joules on 27 kV. When called to energize the Magnetic Actuator coils,
the capacitors will deliver a peak current of approximately 35 A and a pulse width of 45 milliseconds for opening operations and 60 milliseconds for closing operations.
The ED2.0, with external circuitry, system Block Diagram is given in Illustration 1 below.
3.0 BINARY
There is a removable filter card plugged into the ED2.0 board. This filter card has five metal
jumpers on it. When the jumpers are cut, the binary input threshold is raised by 20 V. It is recommended that these be cut for 125 VDC operation.
Binary input channels work properly with a voltage range of 24 to 264 VAC/DC regardless of
which board is used. All inputs have a low threshold at about 18 VDC and 19 VAC with the
exception of the Protection Relay input, which has a low threshold of about 7 VDC. To avoid
false triggering by noise, the inputs must be active for at least 6 milliseconds. The current draw
for most inputs is < 2 milliamperes. The exception is the Remote Open and Close inputs, which
draw up to approximately 20 milliamperes. The input impedance (Z) is 300 kOhms except for
binary inputs 1 and 2 (Remote open and close) which are around 14 kOhms input Z.
There are seven different input channels. Only six of them are used for the R-MAG breaker
(channel 5 is not used).
3.1 Remote Close (KM1005, CH 1, Pins 1 and 2)
The Remote Close input is used to close the breaker remotely. The input impedance is approximately 14 kOhms.
3.2 Remote Open (KM1005, CH 2, Pins 3 and 4)
The Remote Open input is used to trip breaker remotely. The input impedance is approximately
14 kOhms. When tripping with electromechanical relays, an additional resistor will be required to
drop the trip flags.
3.3 Auxiliary Open / Safe Open (KM1005, CH 3, Pins 5 and 6)
This input can be configured as either an Auxiliary Open function or a Safe Open function. The
position of dip switch I1002 determines which is selected. If it is Off, it is used as Auxiliary. If the
dip switch is On, it is used as Safe Open.
The Auxiliary Open functions the same as the Remote Open function, with the exception of the
input impedance which is approximately 300 kOhms.
The Safe Open function allows the user to open the circuit breaker when the on board microcontroller is faulty. During normal conditions, all opening inputs work, but if the microcontroller is
damaged, only the Safe Open input can perform the opening command. When the microcontroller is damaged, capacitor monitoring is not active so other inputs will be ignored. In order for
the breaker to open correctly, there must be sufficient energy in the capacitors.
31
32
THRESHOLD
48 60 VDC
24 30 VDC
NONE
SWITCHING CHARACTERISTICS
Maximum Switching Power
6A
6A
CONTACTS CHARACTERISTICS
Maximum On Resistance (Ron)
Maximum Capacitance
1.5 pF
TIMING CHARACTERISTICS
Maximum Actuating Time
5.0 milliseconds
3.0 milliseconds
INSULATION
Between Contacts and Coil
Resistance (Roff)
ENVIRONMENTAL CHARACTERISTICS
Operating Temperature Range
34
5 million
30,000
5.0 FEATURES
5.1 Temperature Protection
The Temperature Protection circuit monitors the average temperature of a critical area on the
ED2.0 power supply. The output power will be linearly reduced to zero as the temperature
increases from 78 degrees C to 95 degrees C.
5.2 Actuator Close and Trip Coil Continuity Monitor
See Illustration 10 - Troubleshooting Guide.
5.3 Wrong Position Auto Trip
An Auto Trip command will be issued in the event the breaker does not perform a successful
close operation within 95 milliseconds after the close command is issued.
5.4 Energy Failure Auto Trip
CAUTION
If power is removed from unit, and the Dip Switch I1004-1 is placed in the on
position, the breaker will automatically trip in approximately 3 minutes. Make
sure personnel and tools are clear from breaker.
The Energy Failure Auto Trip function is selected by Dip Switch I1004-1 and will cause the breaker to auto trip in the event the capacitor voltage falls below 49 volts. Necessary precautions must
be taken when power is removed (e.g., power removed for maintenance) as the breaker will
automatically trip if I1004-1 is in the On position.
5.5 Reduced Power Consumption
The Reduced Power Consumption setting will lower the power output of the power supply
recharge unit, on the ED2.0 board, from 75 W power to 33 W. This enables the ED2.0 board to
be supplied with the energy delivered by a voltage transformer if necessary. The Power Supply
Recharge Unit is 80% efficient. This means that the Auxiliary Power supply input must be at least
93.75 W for the 75 W setting or 41.3 W for the 33 W setting. The 33 W option is hardware selectable with Jumper JP1019.
5.6 RS-232 Port / JTAG Communication Port
Used by ABB factory only.
35
CLOSE
OPEN
Close allowed
Open allowed
Close allowed
Open allowed
Blocked in closed
position or CB
opened (depending
on dip switch setting
- I1004)
RECHARGE TIME
As with all energy storage devices, there is a recharge time required for operation of the breaker.
A fully charged unit will do an Open-Close-Open operation. Average values for recharge on 15
kV units are listed below. The 27 kV units require additional recharge time. The values shown are
minimums and will change as capacitor life and operation conditions vary.
Open-1.0 sec
Close-2.2 sec
Close-Open-3.4 sec
Open-Close-Open-5 sec
6.1 Discharging Storage Unit Capacitors
WARNING
Make sure ED2.0 Control Power is removed before attempting to discharge the
capacitors. See paragraph below.
36
The ED2.0 board provides access through KM1003 for discharging the Storage Unit capacitors.
Make sure the ED2.0 Control Board Power is removed before attempting to discharge the capacitors.
PROCEDURE:
A 10 kOhm capacitor discharge resistor is mounted on the circuit board. Discharging is done by
jumpering KM1003 pins 4 and 5. The time constant is 33 minutes. An external resistor can be
used for quicker discharging, but the discharge current should be restricted to 10 A maximum.
This means that no lower than 10 Ohms external resistance should be used to perform capacitor
discharging. In this case an external 10 Ohm, 25 watt resistor can be connected to KM1003 Pins
4 and 6. Approximately 30 seconds is needed to discharge the capacitors using the 10 Ohm
external resistor.
6.2 Capacitor Life
The 0.1 Farad Electrolytic capacitors are designed to be operated in the temperature range of 40F to 185F. The End of Life corresponds to the point at which the capacitance decreases by
20% or more.
It is recommended that replacement of capacitors be performed every 15 years for tropical climates and 20 years for an average yearly temperature (in the outdoor breaker enclosure) of less
than 122F.
6.3 Breaker Ready / Not Ready Binary Output Contacts and Ready Light Status
CIRCUIT BREAKER POSITION
CONDITION
CLOSE
OPEN
Ready LED: on
Ready LED: on
Ready contact: closed
Ready contact: closed
Not ready contact: opened Not ready contact: opened
37
On filter card
6
5
4
3
2
1
6
5
4
3
2
1
8.0 DEFAULT JUMPER AND DIP SWITCH SETTINGS REV 02 AND GREATER ED2.0
Unless specified by the customer, the Low Energy and Under Voltage trip functions are disabled.
Input three is set for Auxiliary trip mode as opposed to the Protection Relay trip mode. The
Protection Relay mode has a lower switching threshold (12 V). See Section 3.0 in Appendix A for
Switch and Jumper locations. The following represents the functional Jumper and Dip Switch settings which are the shipped configuration.
P
R
O
T
E
C
T
I
O
N
JP1019
Add Jumper for
33 Watt setting
N
O
R
M
A
L
I1001
1 1
2 2
3 3
On filter card
I1002
I1004
I1004 Energy failure auto trip and UV delay time
2
UV Disabled
OFF
OFF
OFF
UV Delay 500 ms
OFF
ON
OFF
UV Delay 1000 ms
ON
ON
OFF
UV Delay 2000 ms
OFF
OFF
ON
UV Delay 3000 ms
ON
OFF
ON
UV Delay 4000 ms
OFF
ON
ON
UV Delay 5000 ms
ON
ON
ON
1
ON
OFF
1
OFF
ON
3
I1001 UV Threshold
OFF
OFF
ON
220-240 VAC/VDC
OFF
OFF
OFF
100-127 VAC/VDC
ON
OFF
OFF
48-60 VAC/VDC
OFF
ON
OFF
24-30 VAC/VDC
OFF
OFF
ON
39
Plug in
here
KM1007
(BLACK)
(BLACK)
(BROWN)
(BROWN)
I1002
I1004
(BLUE)
(BLUE)
B
B
6
5
4
3
2
1
43
1.
2.
3.
4.
Use diagram on the previous page for references to troubleshooting the ED2.0 board
Disconnect source power to outdoor breaker
Warning: removing cover exposes live voltage
Remove the two #4 screws holding on the Push button plate and let it hang down
5. Remove the four .250 X 20 screws from the corners of the ED2.0 cover
Follow these instructions for a quick setup check on a breaker that has operated previously:
READY LIGHT IS OFF:
1. Check pins 2 and 3 on KM1003 to confirm proper input voltage is applied.
2. Verify that there is 18 VDC on terminals 1 (-) to 3 (+) on KM1001.
3. Verify there is 80 VDC from KM1002 1 (-) to 3 (+).
4. If correct voltage is applied and DC is not reading, then the board needs to be replaced.
READY LIGHT IS ON:
Check proximity sensors located on top of the mechanism. The metal guard will have to be
removed prior to inspection. When the sensor is properly positioned, you will see a yellow light
on the rear of the sensor for each breaker position. When breaker is closed, the upper sensor
will be lit. When open, the lower sensor will be lit. The gap between the sensor and the metal
flag must be not be greater than .045. If this gap is incorrect, the sensor may not see the position
of the breaker.
Upper
sensor
Mechanism
Side
Lower
Sensor
POSSIBLE CAUSES
POSSIBLE SOLUTIONS
There are 3 wires connected to the proximity sensors- Black is the signal wire, Brown is connected
to +18 volts and Blue is connected to ground.
When metal is placed in front of a sensor, it will
be picked up and you will see the yellow LED lit
on the back of the sensor. From the black wire to
the blue wire verify it reads +18V. When the
metal is removed the voltage should drop to near
0.
45
PROBLEMS
POSSIBLE CAUSES
The circuit breaker is closed
and the close coil is
disconnected or broken.
Ready LED
is blinking
The auxiliary supply voltage
has been turned off.
POSSIBLE SOLUTIONS
In this case, only the opening operation is available;
open the circuit breaker (the ready LED will be
turned off) and check the closing coil circuit. Unplug
the magnetic actuator from the plug to the left of the
mechanism (MA). There are two Phillips head
screws that keep the plug held together. The top two
wires are red the bottom two wires are blue. The
bottom red (43) and bottom blue (45) wire go to the
"On" (close) coil. The coil should read between
0.6 -1.0 ohms.
If the circuit breaker is closed you can perform a
CO-operation; connect the auxiliary supply. Check
pins 2 and 3 on KM1003 to confirm proper input
voltage is applied.
Wait a few seconds.
The opening coil is broken or In this case, only the closing operation is available;
damaged.
open the circuit breaker (the ready LED will be
turned off) and check the closing coil circuit.
Disconnect the magnetic actuator from the plug to
the left of the mechanism. There are two Phillips
head screws that keep the plug held together. The
top two wires are red and the bottom two wires are
blue. The top red (43) and top blue (45) wire go to
the "Off" (open) coil. The coil should read between
The opening
0.6 -1.0 ohms.
command is The capacitor bank is not
Check the capacitor bank circuit. Verify the capacinot performed connected.
tors are connected to the control board. Ensure that
there is 80 VDC across KM1002 terminals 1 and 3.
No external opening input is
connected.
The control panel is either
damaged or not connected
correctly.
PROBLEMS
POSSIBLE CAUSES
POSSIBLE SOLUTIONS
Check the closing coil circuit. Disconnect the magnetic actuator from the plug to the left of the mechanism. There are two Phillips head screws that keep
the plug held together. The top two wires are red and
the bottom two wires are blue. The bottom red (43)
and bottom blue (45) wire go to the "On" (close) coil.
The coil should read between 0.6 -1.0 ohms.
One open input is active. Verify there is not a held trip signal on the ED2.0
board. Verify the voltage across TB1-8 and TB1-3 is
"0" (KM1005 3, 4), and also across KM1005 5, 6
Safe open (if used), and KM1005 7, 8 second trip (if
used).
The block in open input is Check the manual trip lever to verify it is in the up
open (manual trip lever).
(normal) position. If it is, verify the microswitch
(mounted on the mechanism side) has continuity
The closing
across the wires.
command is
The capacitor bank is not Check the capacitor bank circuit. Verify the capacinot performed
connected.
tors are connected to the control board. Ensure that
there is 80 VDC across KM1002 terminals 1 and 3.
The ready LED on control See conditions under "Ready LED is off (unit not
panel is off.
ready)".
The control panel is dam- Verify the control panel 6-pin plug is plugged into
aged or not connected
KM1007.
properly.
The energy in the capacitor Ensure the auxiliary supply voltage is connected.
bank is not enough for a
See "ready light blinking" section.
CO-operation.
The circuit
breaker closes
and then opens
during a close
operation
The circuit
breaker opens if
the auxiliary If possible, disable the
function via I1004-1.
supply is
switched off Switch 1 should be in the
off position.
47
5. Before proceeding, discharge the capacitors by jumpering KM1003 pins 4 and 5. The time
constant is 33 minutes. A smaller external resistor can be used for a quicker discharge, but
the discharge current should be restricted to 10 amperes maximum. This means that no
lower than 10 ohms 25 watt external resistance should be used to perform capacitor dis
charging. When discharging with a external capacitor, connect to pins 2 and 3 on KM1002.
6. After the capacitors are discharged, take a small screwdriver and remove the capacitor plug.
48
7. Remove five plugs: KM1001, KM1002, KM1003, KM1004, KM1005, and KM1007. To
remove, loosen hold down screws from each plug.
8. Remove plug for push button plate. This is not held by retainers.
9. Remove four .250-20 nut, lock and flat washer from the four corners. Keep the three rubber
washers behind each screw.
.250 Hex nut
Rubber washer
NOTES
50
NOTES
51
ABB Inc.
655 Century Point
Lake Mary, FL 32746 U.S.A.
For sales & marketing contact your local
representative or:
Tel: +1-407-732-2000
1-800-929-7947
Fax: +1-407-732-2161
www.abb.com/mediumvoltage